Flexible insulation displacement terminal

Abstract

An insulation displacement terminal comprises a first portion, a second portion, and a press-fit pin. The first portion may comprise a first beam and a second beam. A slot is generally formed by a first central edge of the first beam and a second central edge of the second beam. The second portion may comprise a third beam, a fourth beam, and a fifth beam. The fourth beam is configured as a cantilever beam with an attached lower end and a distal end that is able to move between the third beam and the fifth beam. The press-fit pin is generally attached to an edge of the distal end of the fourth beam.

1 . An insulation displacement terminal comprising:
 a first portion comprising a first beam and a second beam, wherein a slot is formed by a first central edge of the first beam and a second central edge of the second beam;   a second portion comprising a third beam, a fourth beam, and a fifth beam, wherein the fourth beam is configured as a cantilever beam with an attached lower end and a distal end that is able to move between the third beam and the fourth beam; and   a press-fit pin attached to an edge of the distal end of the fourth beam.   
     
     
         2 . The insulation displacement terminal according to  claim 1 , wherein the second portion is wider than the first portion. 
     
     
         3 . The insulation displacement terminal according to  claim 1 , wherein the distal end of the fourth beam is wider than the attached lower end of the fourth beam. 
     
     
         4 . The insulation displacement terminal according to  claim 1 , wherein:
 the second portion has a first outer edge comprising a first barb feature and a first shoulder feature and a second outer edge comprising a second barb feature and a second shoulder feature.   
     
     
         5 . The insulation displacement terminal according to  claim 4 , wherein the first barb feature and the second barb feature allow the insulation displacement terminal to rigidly attach to a terminal support feature of a housing of an electronic control module. 
     
     
         6 . The insulation displacement terminal according to  claim 5 , wherein the first shoulder feature and the second shoulder feature allow the insulation displacement terminal to be inserted to a predetermined depth within the terminal support feature of the housing of the electronic control module. 
     
     
         7 . The insulation displacement terminal according to  claim 1 , wherein the fourth beam further comprises one or more holes located adjacent to the edge of the distal end of the fourth beam. 
     
     
         8 . The insulation displacement terminal according to  claim 1 , wherein the slot formed by the first central edge of the first beam and the second central edge of the second beam has an approximate width that is smaller than a diameter of a lead with which the insulation displacement terminal forms an electrical connection. 
     
     
         9 . An apparatus comprising:
 a housing having an inner mounting surface;   a component cradle formed on said inner mounting surface of said housing;   an electronic component mounted within said component cradle, said electronic component having a plurality of leads;   a plurality of terminal support features formed on said inner mounting surface of said housing adjacent to said component cradle, wherein each of said terminal support features comprises two towers separated by a gap and the gap comprises an open upper end and a narrow lower portion that is configured to receive one of said plurality of leads of said electronic component; and   a plurality of flexible insulation displacement terminals, wherein each of said plurality of flexible insulation displacement terminals comprises a first portion comprising a first beam and a second beam, wherein a slot is formed by a first central edge of the first beam and a second central edge of the second beam, the slot has an approximate width that is smaller than a diameter of said one of said plurality of leads, a second portion comprising a third beam, a fourth beam, and a fifth beam, wherein the fourth beam is configured as a cantilever beam with an attached lower end and a distal end that is able to move between the third beam and the fifth beam, and a press-fit pin attached to an edge of the distal end of the cantilever beam, and each of said flexible insulation displacement terminals is pressed into a respective one of said plurality of terminal support features and forms an electrical connection with said slot receiving one of said plurality of leads.   
     
     
         10 . The apparatus according to  claim 9 , wherein said electronic component comprises a charge storage device. 
     
     
         11 . The apparatus according to  claim 9 , wherein the flexible insulation displacement terminals are configured to electrically connect the electronic component mounted within the component cradle to a printed circuit board substrate. 
     
     
         12 . The apparatus according to  claim 11 , wherein said terminal support features are formed on said inner mounting surface of said housing such that said plurality of leads connecting the electronic component to the flexible insulation displacement terminals form a right angle bend. 
     
     
         13 . A method for assembling an electronic control unit, comprising the steps of:
 forming a housing comprising an inner mounting surface, a component cradle formed on the inner mounting surface of the housing, and a plurality of terminal support features formed on the inner mounting surface of the housing;   placing an electronic component on the component cradle and placing a plurality of leads of the electronic component in the plurality of terminal support features; and   press fitting a plurality of flexible insulation displacement terminals in said plurality of terminal support features to form electrical connections with said plurality of leads, wherein each of said plurality of flexible insulation displacement terminals comprises a first portion comprising a first beam and a second beam, wherein a slot is formed by a first central edge of the first beam and a second central edge of the second beam, a second portion comprising a third beam, a fourth beam, and a fifth beam, wherein the fourth beam is configured as a cantilever beam with an attached lower end and a distal end that is able to move between the third beam and the fifth beam, and a press-fit pin attached to an edge of the distal end of the cantilever beam.   
     
     
         14 . The method according to  claim 13 , further comprising:
 attaching a circuit board assembly with an attached connector assembly to the housing such that the press-fit pin of each of the plurality of flexible insulation displacement terminals is press fit into a corresponding via of the circuit board assembly.   
     
     
         15 . The method according to  claim 14 , further comprising:
 laser welding the connector assembly to the housing;   applying at least one of a gasket and a sealant material to the housing; and   assembling a baseplate to the housing.